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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
NASA NTRS1978

Vibration effects of the space shuttle main engine high pressure oxidizer turbopump bellows

A welded metal bellows was subjected to a series of vibration tests in a 400 psi oxygen environment to evaluate the effects of the bellows convolutes rubbing on the damper ring in the high pressure oxidizer turbopump of the space shuttle main engine. The bellows was subjected to approximately 2 million cycles at 0.007 in. double amplitude displacement during this series of tests, at a frequency of 400 Hz. Intrumentation of the test specimen revealed no significant heat buildup caused by the rubbing of the bellows convolutes on the damper ring. A final destruct test was made to determine if a fire would result if the bellows ruptured in the 400 psi oxygen environment, thus exposing a fresh metal surface. The vibration input was changed to 0.8 in. double amplitude displacement at 20 Hz to intentionally rupture the bellows. Failure occurred after 2.5 sec; no fire or heat buildup was encountered.

Harp, J. A.↗
NASA NTRS2015

Monolithic Solid-State Lasers for Spaceflight

A new solution for building high power, solid state lasers for space flight is to fabricate the whole laser resonator in a single (monolithic) structure or alternatively to build a contiguous diffusion bonded or welded structure. Monolithic lasers provide numerous advantages for space flight solid state lasers by minimizing misalignment concerns. The closed cavity is immune to contamination. The number of components is minimized thus increasing reliability. Bragg mirrors serve as the high reflector and output coupler thus minimizing optical coatings and coating damage. The Bragg mirrors also provide spectral and spatial mode selection for high fidelity. The monolithic structure allows short cavities resulting in short pulses. Passive saturable absorber Q-switches provide soft aerturing fro spatial mode filtering and improved pointing stability. We will review our recent commercial and in-house developments toward fully monolithic solid state lasers.

Monolthic laser↗
NASA NTRS1982

Onsite Fabrication of Trusses and Structures

Tribeam truss that is strong and light made at site where used. Reinforced plastic members are fabricated by beam-making machine and assembled by assembly and welding machines. Although proposed for space-platform assembly, concept may be useful in terrestrial applications in remote or inaccessible places.

Bodle, J. G.↗
NASA NTRS1994

Tank Made Of Connected Cooling Fins

New method of fabricating fin-cooled tank requires half as many arc-welding passes and features more efficient transfer of heat. Fins integral parts of tank structure. Requires only one welding pass per fin, and pass done on unobstructed inside of tank. With inside welding, fins longer and more closely spaced. Method proposed to build tank with 256 fins. Holds water in which radioisotope heat source immersed before use. Water absorbs bremsstrahlung radiation from isotope, and fins dissipate heat generated by absorption.

Schultz, Donald F.↗
NASA NTRS2014

Manufacturing Challenges Associated with the Use of Metal Matrix Composites in Aerospace Structures

Metal Matrix Composites (MMCs) consist of a metal alloy reinforced with ceramic particles or fibers. These materials possess a very high strength to weight ratio, good resistance to impact and wear, and a number of other properties which make them attractive for use in aerospace and defense applications. MMCs have found use in the space shuttle orbiter's structural tubing, the Hubble Space Telescope's antenna mast, control surfaces and propulsion systems for aircraft, and tank armors. The size of MMC components is severely limited by difficulties encountered in joining these materials using fusion welding. Melting of the material results in formation of an undesirable phase (formed when molten Aluminum reacts with the reinforcement) which leaves a strength depleted region along the joint line. Friction Stir Welding (FSW) is a relatively nascent solid state joining technique developed at The Welding Institute (TWI) in 1991. The process was first used at NASA to weld the super lightweight external tank for the Space Shuttle. Today FSW is used to join structural components of the Delta IV, Atlas V, and Falcon IX rockets as well as NASA's Orion Crew Exploration Vehicle and Space Launch System. A current focus of FSW research is to extend the process to new materials, such as MMCs, which are difficult to weld using conventional fusion techniques. Since Friction Stir Welding occurs below the melting point of the workpiece material, this deleterious phase is absent in FSW-ed MMC joints. FSW of MMCs is, however, plagued by rapid wear of the welding tool, a consequence of the large discrepancy in hardness between the steel tool and the reinforcement material. This chapter summarizes the challenges encountered when joining MMCs to themselves or to other materials in structures. Specific attention is paid to the influence of process variables in Friction Stir Welding on the wear process characterizes the effect of process parameters (spindle speed, traverse rate, and length of joint) on the wear process. A phenomenological model of the wear process was constructed based on the rotating plug model of Friction Stir Welding. The effectiveness of harder tool materials (such as Tungsten Carbide, high speed steel, and tools with diamond coatings) to combat abrasive wear is also explored. In-process force, torque, and vibration signals are analyzed to assess the feasibility of in situ monitoring of tool shape changes as a result of wear (an advancement which would eliminate the need for off-line evaluation of tool condition during joining). Monitoring, controlling, and reducing tool wear in FSW of MMCs is essential to implementation of these materials in structures (such as launch vehicles) where they would be of maximum benefit. The work presented here is extendable to machining of MMCs, where wear of the tool is also a limiting factor.

Prater, Tracie↗
NASA NTRS1981

Progress in composite structure and space construction systems technology

The development of deployable and fabricated composite trusses for large space structures by NASA and private industry is reviewed. Composite materials technology is discussed with a view toward fabrication processes and the characteristics of finished truss beams. Advances in roll-forming open section caps from graphite-composite strip material and new ultrasonic welding techniques are outlined. Vacuum- and gravity-effect test results show that the ultrasonic welding of graphite-thermoplastic materials in space is feasible. The structural characteristics of a prototype truss segment are presented. A new deployable graphite-composite truss with high packaging density for broad application to large space platforms is described.

Bodle, J. B.↗
NASA NTRS1997

2195 Aluminum-Copper-Lithium Friction Plug Welding Development

Technology developments and applications of friction plug welding is presented. This friction repair welding technology is being studied for implementation on the Space Transportation System's Super Light Weight External Tank. Single plug repairs will be used on a vast majority of weld defects, however, linear defects of up to several inches can be repaired by overlapping plug welds. Methods and results of tensile, bend, simulated service, surface crack tension and other tests at room and cryogenic temperatures is discussed. Attempts to implement Friction Plug Welding has led to both tool and process changes in an attempt to minimize expansive tooling and lengthy implementation times. Process control equipment and data storage methods intended for large scale production will also be addressed. Benefits include increased strength and toughness, decreased weld repair time, automated and highly reliable process, and a lower probability of having to re-repair defect locations.

Takeshita, Rike P.↗
NASA NTRS1992

Microwelding (or cold-welding) of various metallic materials under the ultra-vacuum LDEF experiment AO 138-10

The FRECOPA experimentation, as part of the Long Duration Exposure Facility (LDEF) mission, of mechanical and electrical parts of spacecraft in space ultra-vacuum has demonstrated freedom from any cold welding including microweld effects. This, as theorized, is due to integrity in space of the earthly grown oxygen layer. A further experimentation, a dynamic one this time, could provide a wealth of scientific data, yielding reliable material selecting criteria.

Assie, Jean-Pierre↗
NASA NTRS1998

Friction-Stir Welding of Large Scale Cryogenic Fuel Tanks for Aerospace Applications

The Marshall Space Flight Center has established a facility for the joining of large-scale aluminum-lithium alloy 2195 cryogenic fuel tanks using the friction-stir welding process. Longitudinal welds, approximately five meters in length, were made possible by retrofitting an existing vertical fusion weld system, designed to fabricate tank barrel sections ranging from two to ten meters in diameter. The structural design requirements of the tooling, clamping and the spindle travel system will be described in this paper. Process controls and real-time data acquisition will also be described, and were critical elements contributing to successful weld operation.

Jones, Clyde S., III↗
NASA NTRS2011

Assembly of 5.5-Meter Diameter Developmental Barrel Segments for the Ares I Upper Stage

Full scale assembly welding of Ares I Upper Stage 5.5-Meter diameter cryogenic tank barrel segments has been performed at the Marshall Space Flight Center (MSFC). One full-scale developmental article produced under the Ares 1 Upper Stage project is the Manufacturing Demonstration Article (MDA) Barrel. This presentation will focus on the welded assembly of this barrel section, and associated lessons learned. Among the MDA articles planned on the Ares 1 Program, the Barrel was the first to be completed, primarily because the process of manufacture from piece parts (barrel panels) utilized the most mature friction stir process planned for use on the Ares US program: Conventional fixed pin Friction Stir Welding (FSW). This process is in use on other space launch systems, including the Shuttle s External Tank, the Delta IV common booster core, the Delta II, and the Atlas V rockets. The goals for the MDA Barrel development were several fold: 1) to prove out Marshall Space Flight Center s new Vertical Weld Tool for use in manufacture of cylindrical barrel sections, 2) to serve as a first run for weld qualification to a new weld specification, and 3) to provide a full size cylindrical section for downstream use in precision cleaning and Spray-on Foam Insulation development. The progression leading into the welding of the full size barrel included sub scale panel welding, subscale cylinder welding, a full length confidence weld, and finally, the 3 seamed MDA barrel processing. Lessons learned on this MDA program have been carried forward into the production tooling for the Ares 1 US Program, and in the use of the MSFC VWT in processing other large scale hardware, including two 8.4 meter diameter Shuttle External Tank barrel sections that are currently being used in structural analysis to validate shell buckling models.

Carter, Robert W.↗
NASA NTRS1989

Plating Patches On Heat-Exchanger Jackets

Permanent repairs made without welding. Technique used to repair nickel-alloy nozzle jacket of Space Shuttle main engine. Applicable to other metal heat-exchanger jackets with similar configurations. Does not require welding, brazing, soldering, or other operations involving high temperatures and consequent damage to surrounding areas. Portion of jacket around damaged area removed by grinding and polishing out to edges adjacent to tube/jacket braze bonds. Spaces between tubes filled with wax preventing contamination of spaces during subsequent plating.

Loureiro, Henry↗
NASA NTRSDate not supplied

Model Assisted Probability of Detection for NASA Space Missions

Model assisted probability of detection (MAPOD) uses data from simulations to improve a traditional probability of detection (POD) study. This could include extending the parameter space to reduce uncertainty or substituting experimental data with simulated data to reduce the time and cost of a POD study. In the past MAPOD was difficult due to limited computational resources, but recent innovations in simulation tools and high-performance computing have made this type of high-degree-of-freedom modelling possible, and complex structures have made it necessary. This presentation will summarize the work done by the computational nondestructive evaluation (CNDE) group at NASA Langley Research Center (LaRC) to complete a MAPOD study for phased array ultrasound testing (PAUT) of a friction stir welding (FSW) method to be used on Space Launch System (SLS) structures. The three critical needs for a MAPOD study are a validated and verified model of the inspection technique for the structure being inspected, some experimental POD data, and an uncertainty model for both the model and the experimental data. PAUT was simulated using Extende CIVA’s UT module. The model was validated using laboratory inspection data from NASA Marshall Space Flight Center (MSFC) for a Hit/Miss POD for FSW in 2219-T87 aluminum panels representative of those used in the SLS. This model was then used to simulate flaw sizes that were originally omitted from the original POD study. The results of this new MAPOD study will be presented along with a discussion of the methods and processes used to analyze the original data, selected simulation parameters, and development of the uncertainty model used for the statistical analysis. The goal of this effort is not just to improve the POD study but to demonstrate the value of MAPOD and provide a roadmap for application of MAPOD on future projects.

Elizabeth Gregory↗
NASA NTRSDate not supplied

Model Assisted Probability of Detection for NASA Space Missions

Model assisted probability of detection (MAPOD) uses data from simulations to improve a traditional probability of detection (POD) study. This could include extending the parameter space to reduce uncertainty or substituting experimental data with simulated data to reduce the time and cost of a POD study. In the past MAPOD was difficult due to limited computational resources, but recent innovations in simulation tools and high-performance computing have made this type of high-degree-of-freedom modeling possible, and complex structures have made it necessary. This presentation will summarize the work done by the computational nondestructive evaluation (CNDE) specialists within the Nondestructive Evaluation Sciences branch at NASA Langley Research Center (LaRC) to complete a MAPOD study for phased array ultrasound testing (PAUT) of a friction stir welding (FSW) method to be used on Space Launch System (SLS) structures. The three critical needs for a MAPOD study are a validated and verified model of the inspection technique for the structure being inspected, some experimental POD data, and an uncertainty model for both the model and the experimental data. PAUT was simulated using Extende CIVA’s UT module. The model was validated using laboratory inspection data from NASA Marshall Space Flight Center (MSFC) for a Hit/Miss POD for FSW in 2219-T87 aluminum panels representative of those used in the SLS. This model was then used to simulate flaw sizes that were originally omitted from the original POD study. The results of this new MAPOD study will be presented along with a discussion of the methods and processes used to analyze the original data, selected simulation parameters, and development of the uncertainty model used for the statistical analysis. The goal of this effort is not just to improve the POD study but to demonstrate the value of MAPOD and provide a roadmap for application of MAPOD on future projects.

Elizabeth Gregory↗
NASA NTRS1993

Materials science on parabolic aircraft: The FY 1987-1989 KC-135 microgravity test program

This document covers research results from the KC-135 Materials Science Program managed by MSFC for the period FY87 through FY89. It follows the previous NASA Technical Memorandum for FY84-86 published in August 1988. This volume contains over 30 reports grouped into eight subject areas covering acceleration levels, space flight hardware, transport and interfacial studies, thermodynamics, containerless processing, welding, melt/crucible interactions, and directional solidification. The KC-135 materials science experiments during FY87-89 accomplished direct science, preparation for space flight experiments, and justification for new experiments in orbit.

Curreri, Peter A.↗
NASA NTRS1993

Space Applications Industrial Laser System (SAILS)

A program is underway to develop a YAG laser based materials processing workstation to fly in the cargo bay of the Space Shuttle. This workstation, called Space Applications Industrial Laser System (SAILS), will be capable of cutting and welding steel, aluminum, and Inconel alloys of the type planned for use in constructing the Space Station Freedom. As well as demonstrating the ability of a YAG laser to perform remote (fiber-optic delivered) repair and fabrication operations in space, fundamental data will be collected on these interactions for comparison with terrestrial data and models. The flight system, scheduled to fly in 1996, will be constructed as three modules using standard Get-Away-Special (GAS) canisters. The first module holds the laser head and cooling system, while the second contains a high peak power electrical supply. The third module houses the materials processing workstation and the command and data acquisition subsystems. The laser head and workstation cansisters are linked by a fiber-optic cable to transmit the laser light. The team assembled to carry out this project includes Lumonics Industrial Products (laser), Tennessee Technological University (structural analysis and fabrication), Auburn University Center for Space Power (electrical engineering), University of Waterloo (low-g laser process consulting), and CSTAR/UTSI (data acquisition, control, software, integration, experiment design). This report describes the SAILS program and highlights recent activities undertaken at CSTAR.

Mccay, T. D.↗
NASA NTRS2026

Hybrid Modeling Study on Grain Evolution in the Metal Welding Process and Its Potential Lunar Application

Metal is most commonly used structural material in a wide range of spacecraft, and welding is the principal method for joining metal components into functional systems. However, conducting welding experiments under extreme environments—such as microgravity or vacuum conditions in space—is prohibitively expensive and experimentally challenging. To overcome these limitations, multi-physics computational welding models provide a cost-effective and versatile alternative. In this work, the authors have developed a coupled thermal (fluid) microstructure simulation framework to model metal welding under varying gravity conditions. The framework integrates a mixed-mode heat transfer formulation (conduction, convection, and radiation) with molten pool fluid dynamics, enabling accurate prediction of temperature fields and weld-pool geometry. A grain growth model is further incorporated to capture the spatial and temporal evolution of microstructure, including grain size distribution and morphological transitions during solidification. This approach provides detailed insight into molten pool evolution and grain-level microstructure development throughout the welding process. By explicitly parameterizing environmental conditions, the model supports extrapolation to off-Earth manufacturing scenarios such as welding on the lunar surface. Tantalum—chosen in this study due to its high melting point, oxidation resistance, and mechanical stability at elevated temperatures—serves as the material system for model demonstration. Beyond Tantalum, the integrated multi-physics framework offers broad applicability for predictive welding simulations of various structural and refractory metals or alloys used in extreme terrestrial or extraterrestrial environments.

kinetic Monte Carlo (SPPARKS)↗
NASA NTRS1998

Friction Stir Welding Development

The research of this summer was a continuation of work started during the previous summer faculty fellowship period. The Friction Stir Welding process (FSW) patented by The Welding Institute (TWI), in Great Britain, has become a popular topic at the Marshall Space Flight Center over the past year. Last year it was considered a novel approach to welding but few people took it very seriously as a near term solution. However, due to continued problems with cracks in the new aluminum-lithium space shuttle external tank (ET), the friction stir process is being mobilized at full speed in an effort to mature this process for the potential manufacture of flight hardware. It is now the goal of NASA and Lockheed-Martin Corporation (LMC) to demonstrate a full-scale friction stir welding system capable of welding ET size barrel sections. The objectives this summer were: (1) Implementation and validation of the rotating dynamometer on the MSFC FSW system; (2) Collection of data for FSW process modeling efforts; (3) Specification development for FSW implementation on the vertical weld tool; (4) Controls and user interface development for the adjustable pin tool; and (5) Development of an instrumentation system for the planishing process. The projects started this summer will lead to a full scale friction stir welding system that is expected to produce a friction stir welded shuttle external tank type barrel section. The success of this could lead to the implementation of the friction stir process for manufacturing future shuttle external tanks.

Romine, Peter L.↗